Frac plug device for high expansion at the setting position

Abstract

The frac plug device is a wedge type or ramp type frac plug that can seal at a setting position in a large diameter portion of the borehole. The thickness, taper angle, and dimensions of components for passing through the narrowest portion of the borehole during deployment no longer limit the radial expansion. The frac plug device includes a core cone, a segmented cone, a slip device, a segmented cap member, and a core cap member. A simplified setting action sets the high expansion of the slip device by the core cone and the segmented cone. The segmented cone and the segmented cap member increase expansion of the slip device, and the segmented cap member and the core cap member lock the slip device around the core cone in the final expansion configuration at the maximum radial expansion for large diameter portions of the borehole.

We claim: 
     
       1. A frac plug device, comprising:
 a core cone having first core cone end, a second core cone end opposite said first core cone end, an inner core cone channel extending from said first core cone end to said second core cone end, and a tapered outer core cone surface decreasing in outer core cone diameter toward said second core cone end; 
 a segmented cone having first segmented cone end and a second segmented cone end opposite said first segmented cone end, 
 wherein said segmented cone is comprised of a plurality of cone segments, each cone segment of said plurality of cone segments having an inner cone segment surface and a tapered outer cone segment surface opposite said inner cone segment surface, 
 wherein said tapered outer segment surface has an outer segment diameter decreasing toward said second segmented cone end, and 
 wherein said inner cone segment surface is in sliding engagement with said tapered outer core cone surface; 
 a slip device having a first slip end, a second slip end opposite said first slip end, and an outer slip diameter, 
 wherein said slip device is comprised of a plurality of slip segments, each slip segment of said plurality of slip segments having an inner slip segment surface and an outer slip segment surface opposite said inner slip segment surface, 
 wherein said outer slip segment surface has an engagement means so as to anchor a borehole wall, and 
 wherein said inner slip segment surface is in sliding engagement with a respective tapered outer segmented cone surface of each cone segment of said plurality of cone segments so as to expand each slip segment of said plurality of slip segments with a respective cone segment of said plurality of cone segments; 
 a segmented cap member having a first segmented cap end and a second segmented cap end opposite said first segmented cap end, 
 wherein said segmented cap member is comprised of a plurality of cap segments, each cap segment of said plurality of cap segments having an inner tapered cap segment surface and an outer tapered cap segment surface opposite said inner tapered cap segment surface, and 
 wherein said inner slip segment surface is in sliding and locked engagement with a respective outer tapered cap segment surface of each cap segment of said plurality of cap segments; 
 a core cap member having a first core cap end, a second core cap end opposite said first second cap end, an inner core cap channel extending from said first core cap end to said second core cap end, and a tapered outer core cap surface decreasing in outer core cap diameter toward said first core cap end, 
 wherein said inner tapered cap segment surface is in sliding and locked engagement with said tapered outer core cap surface, 
 wherein said core cone and said core cap member have a full expansion configuration with said second core cone end, said second segmented cone end, said first segmented cap end, and said first core cap end within said slip device, and 
 wherein said outer slip diameter in said full expansion configuration is comprised of said slip device and said outer segment diameter as set by said outer core cone diameter; 
 a segmented cone support ring removably engaged with said plurality of cone segments at said first segmented cone end; and 
 a segmented cap member support ring removably engaged with said plurality of cap segments at said second segmented cap end. 
 
     
     
       2. The frac plug device, according to  claim 1 , wherein each slip segment of said plurality of slip segments is locked in position around said core cone by a respective cap segment of said plurality of cap segment and said core cap member. 
     
     
       3. The frac plug device, according to  claim 1 , further comprising:
 a slip support ring removably engaged with said plurality of slip segments. 
 
     
     
       4. The frac plug device, according to  claim 1 , wherein said core cone and said core cap member have a run-in configuration with said second core cone end at said first segmented cone end, said second segmented cone end at said first slip end, said second slip end at said first segmented cap end, and said second segmented cap end at said first core cap end, and
 wherein said outer slip diameter in said run-in configuration is comprised of said slip device. 
 
     
     
       5. The frac plug device, according to  claim 4 , wherein said core cone and said core cap member have an initial expansion configuration with said second core cone end at said first segmented cone end, said second segmented cone end and said first segmented cap end within said slip device, and said second segmented cap end at said first core cap end, and
 wherein said outer slip diameter in said initial expansion configuration is comprised of said slip device and said outer segment diameter. 
 
     
     
       6. The frac plug device, according to  claim 4 , further comprising:
 a segmented cone support ring removably engaged with said plurality of cone segments at said first segmented cone end; 
 a segmented cap member support ring removably engaged with said plurality of cap segments at said second segmented cap end; and 
 a slip support ring removable engaged with said plurality of slip segments, 
 wherein segmented cone support ring is engaged with said plurality of cone segments and said segmented cap member support ring is engaged with said plurality of cap segments in said initial expansion configuration, and 
 wherein said slip support ring is removed from said plurality of slip segments in said initial expansion configuration. 
 
     
     
       7. The frac plug device, according to  claim 1 , wherein said engagement means is selected from a group consisting of a toothed surface, a grit coating, and protrusions. 
     
     
       8. The frac plug device, according to  claim 1 , wherein said inner slip segment surface is comprised of a first tapered inner slip portion and a second tapered inner slip portion,
 wherein said first tapered inner slip portion is in sliding engagement with said tapered outer segmented cone surface of each cone segment of said plurality of cone segments, and 
 wherein said second tapered inner slip portion is in sliding and locked engagement with a respective outer tapered cap segment surface of a corresponding cap segment of said plurality of cap segments. 
 
     
     
       9. The frac plug device, according to  claim 8 , wherein said first tapered inner slip portion is tapered toward said second tapered inner slip portion. 
     
     
       10. The frac plug device, according to  claim 1 , wherein said inner tapered cap segment surface is comprised of an inner tapered cap ridge, and
 wherein said tapered outer core cap surface is comprised of an outer cap groove in sliding engagement with said inner tapered cap ridge so as to lock each cap segment of said plurality of cap segments around said core cap member. 
 
     
     
       11. A frac plug device, comprising:
 a core cone having first core cone end, a second core cone end opposite said first core cone end, an inner core cone channel extending from said first core cone end to said second core cone end, and a tapered outer core cone surface decreasing in outer core cone diameter toward said second core cone end; 
 a segmented cone having first segmented cone end and a second segmented cone end opposite said first segmented cone end, 
 wherein said segmented cone is comprised of a plurality of cone segments, each cone segment of said plurality of cone segments having an inner cone segment surface and a tapered outer cone segment surface opposite said inner cone segment surface, 
 wherein said tapered outer segment surface has an outer segment diameter decreasing toward said second segmented cone end, and 
 wherein said inner cone segment surface is in sliding engagement with said tapered outer core cone surface; 
 a slip device having a first slip end, a second slip end opposite said first slip end, and an outer slip diameter, 
 wherein said slip device is comprised of a plurality of slip segments, each slip segment of said plurality of slip segments having an inner slip segment surface and an outer slip segment surface opposite said inner slip segment surface, 
 wherein said outer slip segment surface has an engagement means so as to anchor a borehole wall, and 
 wherein said inner slip segment surface is in sliding engagement with a respective tapered outer segmented cone surface of each cone segment of said plurality of cone segments so as to expand each slip segment of said plurality of slip segments with a respective cone segment of said plurality of cone segments; 
 a segmented cap member having a first segmented cap end and a second segmented cap end opposite said first segmented cap end, 
 wherein said segmented cap member is comprised of a plurality of cap segments, each cap segment of said plurality of cap segments having an inner tapered cap segment surface and an outer tapered cap segment surface opposite said inner tapered cap segment surface, and 
 wherein said inner slip segment surface is in sliding and locked engagement with a respective outer tapered cap segment surface of each cap segment of said plurality of cap segments; and 
 a core cap member having a first core cap end, a second core cap end opposite said first second cap end, an inner core cap channel extending from said first core cap end to said second core cap end, and a tapered outer core cap surface decreasing in outer core cap diameter toward said first core cap end, 
 wherein said inner tapered cap segment surface is in sliding and locked engagement with said tapered outer core cap surface, 
 wherein said core cone and said core cap member have a full expansion configuration with said second core cone end, said second segmented cone end, said first segmented cap end, and said first core cap end within said slip device, 
 wherein said outer slip diameter in said full expansion configuration is comprised of said slip device and said outer segment diameter as set by said outer core cone diameter, 
 wherein said outer tapered cap segment surface is comprised of an outer tapered cap groove, and 
 wherein said inner slip segment surface is comprised of an inner slip ridge in sliding engagement with said outer tapered cap groove so as to lock each slip segment of said plurality of slip segments around said segmented cap member. 
 
     
     
       12. The frac plug device, according to  claim 11 , wherein said inner slip segment surface is comprised of a first tapered inner slip portion and a second tapered inner slip portion, and
 wherein said inner slip ridge is on said second tapered inner slip portion. 
 
     
     
       13. A method for sealing a borehole, comprising the steps of:
 deploying a frac plug device in a borehole to a downhole location, said core cone and said core cap member being in said run-in configuration; 
 moving said segmented cone toward said segmented cap member within said slip device; 
 placing said core cone and said core cap member in said initial expansion configuration, said outer slip diameter being comprised of said slip device and said outer segment diameter; 
 moving said core cone toward said core cap member within said slip device; and 
 placing said core cone and said core cap member in said full expansion configuration, said outer slip diameter being comprised of said slip device and said outer segment diameter as set by said outer core cone diameter, 
 wherein said frac plus device comprises: 
 a core cone having first core cone end, a second core cone end opposite said first core cone end, an inner core cone channel extending from said first core cone end to said second core cone end, and a tapered outer core cone surface decreasing in outer core cone diameter toward said second core cone end; 
 a segmented cone having first segmented cone end and a second segmented cone end opposite said first segmented cone end, 
 wherein said segmented cone is comprised of a plurality of cone segments, each cone segment of said plurality of cone segments having an inner cone segment surface and a tapered outer cone segment surface opposite said inner cone segment surface, 
 wherein said tapered outer segment surface has an outer segment diameter decreasing toward said second segmented cone end, and 
 wherein said inner cone segment surface is in sliding engagement with said tapered outer core cone surface; 
 a slip device having a first slip end, a second slip end opposite said first slip end, and an outer slip diameter, 
 wherein said slip device is comprised of a plurality of slip segments, each slip segment of said plurality of slip segments having an inner slip segment surface and an outer slip segment surface opposite said inner slip segment surface, 
 wherein said outer slip segment surface has an engagement means so as to anchor a borehole wall, and 
 wherein said inner slip segment surface is in sliding engagement with a respective tapered outer segmented cone surface of each cone segment of said plurality of cone segments so as to expand each slip segment of said plurality of slip segments with a respective cone segment of said plurality of cone segments; 
 a segmented cap member having a first segmented cap end and a second segmented cap end opposite said first segmented cap end, 
 wherein said segmented cap member is comprised of a plurality of cap segments, each cap segment of said plurality of cap segments having an inner tapered cap segment surface and an outer tapered cap segment surface opposite said inner tapered cap segment surface, and 
 wherein said inner slip segment surface is in sliding and locked engagement with a respective outer tapered cap segment surface of each cap segment of said plurality of cap segments; 
 a core cap member having a first core cap end, a second core cap end opposite said first second cap end, an inner core cap channel extending from said first core cap end to said second core cap end, and a tapered outer core cap surface decreasing in outer core cap diameter toward said first core cap end, 
 wherein said inner tapered cap segment surface is in sliding and locked engagement with said tapered outer core cap surface, 
 wherein said core cone and said core cap member have a full expansion configuration with said second core cone end, said second segmented cone end, said first segmented cap end, and said first core cap end within said slip device, 
 wherein said outer slip diameter in said full expansion configuration is comprised of said slip device and said outer segment diameter as set by said outer core cone diameter, 
 wherein said core cone and said core cap member have a run-in configuration with said second core cone end at said first segmented cone end, said second segmented cone end at said first slip end, said second slip end at said first segmented cap end, and said second segmented cap end at said first core cap end, 
 wherein said outer slip diameter in said run-in configuration is comprised of said slip device, 
 wherein said core cone and said core cap member have an initial expansion configuration with said second core cone end at said first segmented cone end, said second segmented cone end and said first segmented cap end within said slip device, and said second segmented cap end at said first core cap end, and 
 wherein said outer slip diameter in said initial expansion configuration is comprised of said slip device and said outer segment diameter; 
 a segmented cone support ring removably engaged with said plurality of cone segments at said first segmented cone end; 
 a segmented cap member support ring removably engaged with said plurality of cap segments at said second segmented cap end; and 
 a slip support ring removably engaged with said plurality of slip segments, 
 wherein said segmented cone support ring is engaged with said plurality of cone segments, said segmented cap member support ring is engaged with said plurality of cap segments, and said slip support ring is engaged with said plurality of slip segments in said run-in configuration. 
 
     
     
       14. The method for sealing, according to  claim 13 , wherein said segmented cone support ring is engaged with said plurality of cone segments and said segmented cap member support ring is engaged with said plurality of cap segments in said initial expansion configuration, and
 wherein said slip support ring is removed from said plurality of slip segments in said initial expansion configuration. 
 
     
     
       15. The method for sealing, according to  claim 13 , wherein said segmented cone support ring is removed from said plurality of cone segments, wherein said segmented cap member support ring is removed from said plurality of cap segments, and wherein said slip support ring is removed from said plurality of slip segments in said full expansion configuration. 
     
     
       16. The method for sealing, according to  claim 13 , wherein the step of placing said core cone and said core cap member in said full expansion configuration further comprises the step of:
 locking said slip device around said core cone in said full expansion configuration. 
 
     
     
       17. The method for sealing, according to  claim 16 , wherein the step of locking said slip device around said core one comprising:
 sliding said inner slip segment surface along a respective outer tapered cap segment surface of each cap segment of said plurality of cap segments; and 
 sliding said inner tapered cap segment surface along a respective tapered outer core cap surface. 
 
     
     
       18. The method for sealing, according to  claim 17 , wherein said outer tapered cap segment surface is comprised of an outer tapered cap groove,
 wherein said inner slip segment surface is comprised of an inner slip ridge so as to lock each slip segment of said plurality of slip segments around said segmented cap member, 
 wherein said inner tapered cap segment surface is comprised of an inner tapered cap ridge, and 
 wherein said tapered outer core cap surface is comprised of an outer cap groove so as to lock each cap segment of said plurality of cap segments around said core cap member.